Method for manufacturing a vending machine for serving extremely cold frozen product and method for distributing same

ABSTRACT

The present invention is generally directed to a method for modifying a vending machine to provide a vending machine for storing product at a temperature no greater than −40 degrees Celsius. The method of the invention includes the steps of replacing an existing refrigeration compressor with a different compressor having a higher compression and replacing an existing refrigerant with a more efficient refrigerant. Then, the length of an existing capillary tube was increased (preferably to approximately 21 inches). Finally, a new thermostat capable of achieving a −40 Celsius set point. In addition, in the preferred embodiment, the pre-existing thermostat was rewired into a safety switch, which is operable to disable the vending machine from dispensing product if the temperature exceeds the set point. A novel business method is also provided; namely a method of manufacturing and distributing ice cream. In accordance with this method, a novelty ice cream product is manufactured to take on a beaded and free-flowing form. This ice cream product is then shipped and distributed through vending machines capable of maintaining temperatures sufficiently cold to preserve the beaded and free-flowing form of the ice cream product.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a division of U.S. patent application Ser. No. 09/596,596, filedon Jun. 16, 2000, which claimed the benefit of U.S. provisional patentapplication Ser. No. 60/140,333, filed Jun. 21, 1999.

The present application also claims the benefit of U.S. provisionalpatent application Ser. No. 60/140,333, filed Jun. 21, 1999, andentitled Method for Manufacturing a Vending Machine for ServingSupercooled Product.

FIELD OF THE INVENTION

The present invention relates generally to a frozen product dispensingmethods and apparatus and, more particularly, to a method for modifyinga vending machine for serving an extremely cold frozen product.

DESCRIPTION OF THE PRIOR ART

Vending machines are known for dispensing ice cream and other frozenproduct. However, the temperatures maintained by such machines vary, andare often slightly below freezing. Certain frozen product, however, mustbe maintained at temperatures well below freezing. Indeed some productmay be maintained at temperatures well below zero.

For example, one such product that is marketed by the Applicant hereinis a unique novelty ice cream, frozen yogurt, and ice product in theform of beads. This product, marketed under the trademarks “Dippin'Dots®” and “Ice Cream of the Future®”), has become very popular inspecialty stores and at fairs and theme parks. Indeed, the Applicant hasproprietary rights in the method of preparing and storing the productpursuant to U.S. Pat. No. 5,126,156, issued Jun. 30, 1992, hereinincorporated by reference, as well as rights associated withimprovements pursuant to U.S. Pat. No. 5,664,422, issued Sep. 9, 1997,and U.S. Pat. No. 6,000,229, issued Dec. 14, 1999, both of which areherein incorporated by reference. As is generally described therein, thepatented method involves delivering flavored liquid dairy and otheralimentary compositions to a feed tray and then dripping the compositioninto a freezing chamber. The feed tray comprises a plurality of orificesthrough which liquid composition passes so that droplets form and fallinto the freezing chamber. Each orifice may also have a correspondingfeed dropper, which is downwardly disposed in relation to the tray suchthat the liquid composition passes from the tray through an orifice andthen through an associated feed dropper where a droplet is formed. Theorifices or combination of orifices and feed droppers will hereinafterbe referred to collectively as feed assemblies.

The falling droplets of liquid composition freeze rapidly in thefreezing chamber due to the presence of both gaseous and liquidrefrigerant in the area between the orifices and the bottom of thefreezing chamber, thereby forming solid beads of flavored ice cream,yogurt or other alimentary products, such as flavored ice. The frozenbeads are removed from the freezing chamber and packed for distributionand later consumption. It is important that the frozen beads be stored(throughout the period from the time of initial manufacture to the timeof serving) at temperatures well below freezing, so that the frozenbeads do not tend to fuse together. Therefore, when served, the beadsmaintain a distinct granularity, which has been deemed highly desirablein the product.

In order to capture further markets and expand further into certainmarkets, it is desired to market the product through additionalchannels. One such channel is through vending machines. A problem,however, has been encountered in attempting to penetrate this market.Specifically, the vending machines known by Applicant do not maintaintemperatures cold enough to preserve the integrity of Applicant's frozenbeaded ice cream product.

SUMMARY OF THE INVENTION

Certain objects, advantages and novel features of the invention will beset forth in part in the description that follows and in part willbecome apparent to those skilled in the art upon examination of thefollowing or may be learned with the practice of the invention. Theobjects and advantages of the invention may be realized and obtained bymeans of the instrumentalities and combinations particularly pointed outin the appended claims.

To achieve the advantages and novel features, the present invention isgenerally directed to a method for modifying a vending machine toprovide a vending machine for storing product at a temperature nogreater than −40 degrees Celsius. The method of the invention includesthe steps of replacing an existing refrigeration compressor with adifferent compressor having a higher compression and replacing anexisting refrigerant with a more efficient refrigerant. Then, the lengthof an existing capillary tube was increased (preferably to approximately21 inches). Finally, a new thermostat capable of achieving a −40 Celsiusset point. In addition, in the preferred embodiment, the pre-existingthermostat was rewired into a safety switch, which is operable todisable the vending machine from dispensing product if the temperatureexceeds the set point.

A novel business method is also provided; namely a method ofmanufacturing and distributing ice cream. In accordance with thismethod, a novelty ice cream product is manufactured to take on a beadedand free-flowing form. This ice cream product is then shipped anddistributed through vending machines capable of maintaining temperaturessufficiently cold to preserve the beaded and free-flowing form of theice cream product.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of thespecification, illustrate several aspects of the present invention, andtogether with the description serve to explain the principles of theinvention. In the drawings:

FIG. 1 is a perspective view of an ice cream vending machine constructedin accordance with the invention;

FIG. 2 is an exploded perspective view of the ice cream vending machineof FIG. I;

FIG. 3 is a cross-sectional front view, as taken substantially alongline 3—3 of FIG. 1, with a serving arm retracted;

FIG. 4 is a cross-sectional front view, similar to the view of FIG. 3,but depicting the serving arm extended to retrieve an ice cream product;

FIG. 5 is a cross-sectional front view, similar to the view of FIG. 3,but depicting the serving arm retracted with a retrieved ice creamproduct;

FIG. 6 is a diagram illustrating the primary components of arefrigeration system;

FIG. 7 is a flowchart illustrating the basic steps in the procedure ofthe present invention, which modifies a commercially-available vendingmachine to allow it to reach the extremely cold temperatures of thevending machine of the preferred embodiment; and

FIG. 8 is a flowchart illustrating steps in a novel method ofmanufacturing and distributing ice cream, in accordance with oneembodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Having summarized various aspects of the present invention, referencewill now be made in detail to the description of the invention asillustrated in the drawings. While the invention will be described inconnection with these drawings, there is no intent to limit it to theembodiment or embodiments disclosed therein. On the contrary, the intentis to cover all alternatives, modifications and equivalents includedwithin the spirit and scope of the invention as defined by the appendedclaims.

Accordingly, the present invention is generally directed to an improvedvending machine for dispensing frozen product. In accordance with oneaspect of the present invention, the present invention is directed to amethod of modifying an existing vending machine to improve itstemperature qualities, and specifically lower the temperaturesmaintained by the vending machine to an extent heretofore unreached byother frozen product vending machines. FIG. 1 illustrates a perspectiveview of a vending machine 100, of the type that may be modified inaccordance with the invention to vend frozen product.

Reference is now made to FIG. 2, which is to be considered inconjunction with FIG. 1. In this regard, FIG. 2 is an explodedperspective view of the vending machine 100 of FIG. 1. The vendingmachine 100 is primarily comprised of two parts: a body 102 and afreezer chest 104. The body 102 defines an upright vending machinehaving an front door 106 that is hinged along one edge for movementbetween open and closed positions. The door 106 is illustrated in itsclosed position in FIG. 1, and is illustrated in its open position inFIG. 2. The body 102 of the vending machine 100 defines an interiorspace or chamber that can be viewed as having an upper portion and alower portion. The lower portion houses the freezer chest 104, while theupper portion (as better illustrated in FIGS. 3-5) provides a space fora motorized serving our 110 to move. The operation of the serving arm110 will be described in more detail in connection with FIGS. 3-5 below.

The freezer chest 104 generally operates and a fashion that is wellknown and refrigeration industry to maintain products toward therein ata very cold temperature. However, in accordance with the presentinvention, the freezer chest 104 is modified to attain extremely coldtemperatures. In the preferred embodiment, the product that must bestored within the freezer chest 104 is a novelty ice cream that requirestorage temperatures of at least −40 degrees Celsius. To facilitateordered storage and vending of the product in multiple flavors, thefreezer chest 104 includes a matrix of interior partitions that allowmultiple servings of the ice cream product to be stored in row-columnfashion.

The freezer chest 104 includes a lid 112 that overlies the top of thefreezer chest, and is hinged along one edge for movement between openand closed positions. As can be seen in FIG. 1, unless the vendingmachine 100 is otherwise in operation, the lid 112 of the freezer chest104 remains and closed position to maintain the temperature within thefreezer chest 104 that it's coldest possible temperature. However, whenthe vending machine is in active operation (i.e., a user has selected aproduct for dispensing), the lid 112 of the freezer chest is opened by amotor (not shown) so that he motorized serving arm 110 may retrieve andice cream product from within the freezer chest 104.

To illustrate the dispensing operation of the vending machine 100 of thepresent invention, reference is now made to FIGS. 3-5, which illustratea portion of the vending operation of the vending machine 100. FIGS.3,4, and 5, reach cross-sectional front views has taken substantiallyalong line 3—3 of FIG. 1. FIG. 3 illustrates the state of the vendingmachine 100 shortly after payment has been deposited and a productselection made, as from a front panel 130 (FIG. 1) of the vendingmachine 100. To in this state, the lid 112 of the freezer chest 104 hasbeen moved to its open position. After the lid 112 has been raised toexpose the product stored within the freezer chest 104, the serving arm110 then moves into position to retrieve the selected product. In thisregard, many flavors of the product 120 may be available. Separateflavors may be uniquely stored in specific bins within the freezer chest104. The serving arm 110 may move along tracks and the X and Ydirections to align with the storage bin of the selected product. Then,as illustrated in FIG. 4, a the selection arm 110 may be lowered untilit comes in contact with a product 120. Then, as illustrated in FIG. 5,the serving our may be retracted, thereby raising the selected product120 along with it. In this regard, the preferred embodiment of thevending machine 100 will include a vacuum—operated serving arm 110.Accordingly, the product 120 may be retrieved from the freezer chest 104to the use of vacuum suction. Although not specifically illustrated,once the serving arm 110 has retrieved the selected product from thefreezer chest 104, the serving arm may move toward the front of thevending machine 100, where the suction/vacuum may be discontinuedallowing the selected product 120 to be dropped into a dispensing tray140 (FIG. 1), wherein may be retrieved by the user.

The structure and operation of the vending machine 100 as describedabove should be well appreciated by persons in the vending machine art,and no further description is deemed necessary for an adequateunderstanding of the basic structure and operation of the vendingmachine 100 of the present invention.

Having described the basic structure and operation of the vendingmachine 100, reference is made to FIG. 6, which illustrates the basiccomponents and principles involved in refrigeration systems. As isknown, the basic principles of refrigeration are derived from thebehavior of a suitable fluid when it changes its state from liquid togas or from gas to liquid. Compressing a gas causes its temperature torise, and if its temperature is then reduced without reducing thepressure, the gas will liquify. On the other hand, reducing the pressureof liquefied gas will make it vaporize.

In a refrigeration system 200, the refrigerant or working fluid isevaporated in the evaporator 202, which is placed within therefrigerated compartment 204, and the latent heat is drawn from withinthe compartment, thus reducing its temperature. The working fluid thenpasses to a condenser unit 206 placed outside the refrigeratedcompartment 204, where it is condensed back to a liquid. On condensing,it releases its latent heat, which is the heat it absorbed from therefrigerated compartment 204. As the cycle continues, the refrigerantremoves heat from the compartment and releases it to the surroundingatmosphere.

The temperature within the refrigerated area is regulated by athermostat 208, which controls the rate of circulation of therefrigerant, and thus the amount of cooling.

As is further known, there are both absorption systems and compressionsystems. The compression type of system uses a compressor unit 210 tocirculate the refrigerant. This compressor 210 may be belt driven by anelectric motor, or may be an integral unit containing an electric motorwith a compressor fitted to the end of its shaft. The low-pressure sideof the compressor 210 is connected to the evaporator 202 andhigh-pressure side of the compressor is connected to the condenser 206.The high-pressure refrigerant vapor from the compressor 210 isrelatively hot, and is condensed by maintaining the high-pressure andreducing the temperature. The temperature reduction is achieved bycooling the condenser, either by using a fan driven by the compressormotor to force air through it, or by using a water-cooled condenser. Onsmall systems, the heat may simply be dissipated to the atmosphere bymeans of cooling fins.

The refrigerant passes to the evaporator 202 through a valve thatmaintains the pressure difference between the condenser and theevaporator. The refrigerant is drawn through the evaporator by thelow-pressure created by the condenser, and as it evaporates it absorbsheat from the refrigerated area.

With regard to refrigerants, there are a number of fluids suitable foruse as refrigerants in compression systems, including carbon dioxide(CO₂) and sulfur dioxide (SO₂), but the most useful are the group ofhalogenated hydrocarbons known as freons, including freon-12(dichlorodifluoromethane, CCl₂F₂), freon-11 (trichloromonofluoromethane,CCl₃F₄ ), freon-113 (trichlorotrifluoroethane, C₂ Cl₃F₃), and freon-114(dichlorotetrafluoroethane, C₂Cl₂F₄).

Having set forth the foregoing information regarding refrigerationsystems, the preferred embodiment of the present invention was achievedby modifying a pre-manufactured system. Specifically, a vending machinemanufactured by Fastcorp, specifically the Fastcorp model F631 frozenmerchandiser, was modified. As is known, the Fastcorp F631 came standardwith a product operating storage temperature of approximately −28degrees Celsius. However, the desired system for the Applicant's frozenproduct, sought a storage temperature of −40 degrees Celsius.

The first step in one embodiment of the invention was to replace thestandard refrigeration compressor 210 with a different compressor havinga higher compression. Also, the refrigerant, if different, is replacedwith HP 80, an efficient refrigerant. The combination of the highercompression with the new refrigerant realized lower storagetemperatures.

In addition, the length of the capillary tube 220 was increased toapproximately 21 inches. The capillary tube 220 is a coiled tube that isdisposed in-line with the refrigerant line and operates as a meteringdevice, much like an expansion valve. As refrigerant enters theevaporator, the lengthened capillary tube 220 meters the right amount ofrefrigerant.

In addition, a process port 222 may be installed and used forwithdrawing the 134A refrigerant that comes standard in the F631 frozenmerchandiser. This same port 222 may also be used to add the HP80refrigerant.

In the preferred embodiment, a Dan Foss thermostat 208 is installed forachieving the −40 Celsius set point. The thermostat 208 generates anelectrical output signal that is indicative of the temperature withinthe refrigerated chamber 204. This signal is input to a controller 230,which operates to control the circulation of the refrigerant within therefrigerant line, and therefore controls the temperature within therefrigerated chamber 204. The existing thermostat 226 (a Ramcothermostat) is rewired into the control system for a health safetyswitch 228. The health safety switch 228 disables the unit from vendingif the temperature of the storage freezer exceeds the set point.

Reference is now made to FIG. 7, which is a flowchart illustrating theprincipal steps involved in modifying an existing ice cream vendingmachine to allow the existing machine to reach extremely coldtemperatures. As illustrated in FIG. 7, and as mentioned above, a methodin accordance with the invention includes the step of installing aprocessing port in connection with a refrigerant line (step 304). Themethod then replaces an existing refrigerant (134A) with a moreefficient refrigerant by using the processing port (step 306). In thepreferred embodiment, the more efficient refrigerant is HP80refrigerant. An additional thermostat, capable of achieving a −40Celsius set point, is then installed (step 310). In the preferredembodiment the additional thermostat is a Dan Foss thermostat. Finally,the existing thermostat (a Ramco thermostat) is rewired into a safetyswitch (step 312). This safety switch operates to disable the vendingmachine from dispensing product if the temperature within the freezerexceeds the set point.

It should be appreciated that the steps illustrated in FIG. 7 need notbe performed in the order illustrated in the figure. Furthermore,consistent with the scope and spirit of the invention, some of the stepsmay be modified, or even omitted altogether.

In accordance with a related aspect of the invention, the presentinvention provides a novel business method for distributing ice cream.Reference is made to FIG. 8, which illustrates this distribution method.In accordance with the novel business method, a beaded, free-flowing icecream is manufactured (step 402). This manufacturing step may be carriedout in any of a variety of ways, including methods described in U.S.Pat. No. 5,126,156, U.S. Pat. No. 5,664,422, and U.S. Pat. No.6,000,229. The beaded ice cream is then injected, inserted, or otherwiseplaced into individual serving containers (step 404). These containersmay be semi-rigid, cylindrically-shaped containers, flexible packets, orother appropriate ice-cream storage containers. The packaged, individualserving ice cream portions are then stored and maintained at extremelycold temperatures (step 406). In this regard, the ice cream is stored atemperatures that are cold enough to prevent the ice cream beads fromfusing together. In the preferred embodiment, the storage temperature ismaintained a no greater than −40 degrees Celsius.

The stored ice cream and containers are then shipped to vendingdestination (step 408). The ice cream product may be shipped in freezerunits or other appropriate shipping mechanisms to preserve the extremelycold temperature needed to preserve the beaded form of the ice cream.Once at the shipping location, the ice cream product is stocked within avending machine (step 410). Thereafter, consumers may purchaseindividual servings of ice cream from the vending machine by insertingmoney into the vending machine and making a product selection. Inaccordance with an alternative embodiment, the ice cream may be stockedwithin a vending machine at the location of manufacture, and then theentire vending machine may be shipped to a vending location.

Preferably, the vending machine is that has been modified according tothe method described above. However, consistent with the scope andspirit of the inventive distribution method, the vending machine needonly be one capable of maintaining a temperature sufficiently cold topreserve the beaded and free-flowing form of the ice cream product. Forexample, in an alternative embodiment, a higher capacity compressor mayalso be installed in place of the original compressor. Also, thecapillary tube may be increased to approximately 21 inches.

The foregoing description has been presented for purposes ofillustration and description. It is not intended to be exhaustive or tolimit the invention to the precise forms disclosed. Obviousmodifications or variations are possible in light of the aboveteachings. The embodiment or embodiments discussed were chosen anddescribed to provide the best illustration of the principles of theinvention and its practical application to thereby enable one ofordinary skill in the art to utilize the invention in variousembodiments and with various modifications as are suited to theparticular use contemplated. All such modifications and variations arewithin the scope of the invention as determined by the appended claimswhen interpreted in accordance with the breadth to which they are fairlyand legally entitled.

What is claimed is:
 1. A method for manufacturing and distributing anice cream product comprising: manufacturing an ice cream product in abeaded, free-flowing form, utilizing an extremely cold processingtemperature; packaging the beaded ice cream product in small individualserving containers; shipping the beaded ice cream product to a vendingdestination, and maintaining an extremely cold temperature throughoutpackaging and shipping steps, the extremely cold temperature being atemperature sufficient to maintain the beaded and free-flowing form ofthe ice cream product; and transferring the beaded ice cream productinto a vending machine, the vending machine adapted to vend individualservings of the ice cream product, the vending machine being capable ofmaintaining a temperature sufficient to maintain the beaded andfree-flowing form of the ice cream product.
 2. The method as defined inclaim 1, wherein the step of manufacturing is performed by introducing aproduct in liquid form into a chamber containing liquid nitrogen.
 3. Amethod for manufacturing and distributing an ice cream productcomprising: manufacturing an ice cream product in a beaded, free-flowingform, utilizing an extremely cold processing temperature; packaging thebeaded ice cream product in small individual serving containers;transferring the beaded ice cream product into a vending machine capableof maintaining a temperature sufficiently cold enough to maintain thebeaded and freeflowing form of the ice cream product; shipping thevending machine and beaded ice cream product to a vending destination.